Acoustical shell construction



May 2, @967 J. c. JAFFE ETAL 3,315,999

ACOUSTICAL SHELL CONSTRUCTION 2 Sheets-Sheet 1 Original Filed Aug. 20, 1962 MG. L

V INVENTORS J. CHRISTOPHER JAFFE PAUL KLEINMAN BY ATTORNEYS.

m y 1967 J. C.JAFF'E ETAL ACOUSTICAL SHELL CONSTRUCTION 2 Sheets-Sheet 2 lNVENTORS- I J. CHRISTOPHER JAFFE PAUL KLEINMAN Original Filed Aug. 20, 1962 ATTORNEYS.

3,316,999 ACOUSTICAL SHELL CONSTRUCTION John Christopher Jafie, 2 Stonecrop Road, Norwalk, Conn. 06851, and Paul Kleinman, White Plains, N.Y.; said Kleinman assignor to said J alfe Continuation of application Ser. No. 217,853, Aug. 20, 1962. This application Nov. 5, 1965, Ser. No. 514,164 6 (llaims. (Cl. 181-30) This application is a continuation of application Ser. No. 217,853, filed Aug. 20, 1962, and now abandoned.

This invention relates to acoustical shells and, more particularly, to a novel modular portable acoustical shell construction which is essentially self-supporting and which does not require a separate acoustical roof.

Port-able or removable acoustical shells are used to improve the sound reflecting or acoustical properties of armories, gymanisums and the like for instrumental or vocal concert purposes, as well as being used for outdoor performances of the same type. Known acoustical shell constructions have been expensive, cumbersome, heavy and diflicult to erect. Thus, for example, one known construction involves a series of substantially vertical panels which must be mounted and braced in upright position, and a second series of ceiling panels which must be suitably supported by an overhead structure or the like.

In accordance with the present invention, an acoustic shell construction is provided involving a plurality of relatively rigid panels of sound-reflecting material arranged to be secured together in substantially abutting juxtaposed upright relation to form the shell, the assembled shells and the individual shells being supported by bracket means secured to the panel. By a novel construction of the supporting means for each panel, the latter may be maintained upright despite irregularities in the level of the supporting surface, such as the ground, a stage, a platform, or other supporting surface.

A particular feature of the invention is the acoustical construction of each panel. Thus, each panel comprises a relatively elongated and substantially rectilinear normally upright section merging smoothly at its upper end into an upwardly and forwardly extending roof arch. The provision of a roof arch integral with the upright section and extending forwardly therefrom eliminates the necessity for an acoustical roof or ceiling in association with the shell. The upright section is cylindric in horizontal cross section, with a convexly curved forward surface, and at least the terminal portion of the roof arch is generally cylindrical about a normally horizontal axis, with the cylindric surface or surfaces of the upright section merging into the generally cylindrical surface of the roof arch.

Preferably, the panels are formed with side flanges which are apertured to receive bolts or the like securing adjacent panels to each other, and the panels may be additionally provided with cleats or the like on a rear surface whereby they may be erected in position simply by being roped or tied together utilizing these cleats.

The panels may take either one of two forms. In one form, the side edges of the upright sections are parallel and extend substantially perpendicular to its supporting surface, but the side edges of the roof arch converge toward each other in a forward direction. This type of panel may be used to form a shell which is curved in a horizontal plane about either a relatively large or a relatively small radius of curvature, and may form a completely self-supporting structure. To provide a shell which is rectilinear in a horizontal plane, triangular inserts may be used between the roof arches of adjacent such panels to fill out the space therein so that the panels are all parallel to each other and the shell extends along a relatively straight line. Alternatively, not only the side edges of the upright section but also the side edges of the roof arch may be con- United States Patent "ice tinuous and parallel to each other, and generally perpendicular to the supporting surface. This permits the erection of a shell which extends in a straight line or essentially single vertical plane from one end to the other.

The individual panels are molded of a suitable soundreflecting material, such as, for example, a fiber glass reinforced plastic composition material.

For an understanding of the principles of the invention, reference is made to the following description of typical embodiments thereof as illustrated in the accompanying drawings. In the drawings:

FIG. 1 is a partial front elevational view of a transversely curved acoustical shell embodying the invention;

FIG. 2 is a rear elevational view of one of the panels forming the acoustical shell of FIG. 1;

FIG. 3 is a side elevational view of the panel, showing one support arrangement;

FIGS. 4 through 7 are sectional views on the correspondingly numbered section lines of FIG. 3;

FIG. 8 is a perspective view illustrating a different support arrangement for the panel; 7

FIG. 9 is a partial front elevational view of an acoustical shell extending in substantially a straight line, and illustrating inserts used with the shells of FIG. 1 to correct" the curvature; and

FIG. 10 is a view of a shell similar to that shown in FIG. 9 but illustrating a modified form of panel for use in a rectilinearly extending shell.

Referring first to FIGS. 1 through 7, an acoustical shell 15 is illustrated in FIG. 1 as made up of a plurality of separate panels 20 embodying the invention and secured together at adjacent side edges in upright juxtaposed relation. It will be noted that the acoustical shell of FIG. 1 is curved longitudinally in a horizontal plane, this being due to the particular type panel 20 used to form the shell 15.

Referring to FIGS. 2 and 3, each panel 20 used in the shell 15 of FIG. 1 includes a generally upright section 21 which is substantially rectangular in elevation, upright section 21 merging with a roof arch portion 22 which extends upwardly and forwardly in a smooth curve from the upper end of section 21. While upright section 21 is substantially rectangular in elevation, the roof arch portion 22 has its side edges tapering toward each other from the juncture with section 21 to the terminal portion of roof arch 22. The purpose of this will be made apparent as the description proceeds.

The panels 20, and particularly the upright sections 21 thereof, are so shaped that, in elevation, the shell 15 formed therein is polycylindric insofar as its front surface is concerned, as may be best seen from FIG. 1. To this end, each of the upright sections 21 is formed with at least one, and preferably two or more, partially cylindrical forwardly convex and upwardly extending surfaces, as indicated at 25. In the particular embodiment of the invention illustrated in the drawings, each panel has a pair of three upwardly extending semicylindrical surfaces.

It has been found that a surface of this type provides excellent sound dispersing and reflection properties.

The cylindrical surfaces 25 are of substantially uniform depth, with respect to a vertical plane, throughout the extent of the upright sections 21 but, as the cylindrical surfaces merge into the roof arch 22, they gradually decrease or taper in depth so as to terminate just short of the terminal end of the roof arch 22. Thus, the terminal portion of the roof arch is a cylindrical surface about a substantially horizontal axis, and is substantially a plane cylindrical terminal surface of the roof arch with the upright extending cylindrical protrusions 25 of the upright portions 2 1, which merge into the roof arch, provide increased acoustical effects.

The extreme outer end of the roof arch extend-s substantially vertically, as indicated at 23, so that when the panels are placed in juxtaposed relation to form a shell, the upwar-dly extending portions 23 provide what may be termed a top border for the shell. It will be noted that these portions 23 merge smoothly into the remainder of the roof arch.

The side edges of each panel are bordered by flanges 26 and 27 'which extend rearwardly from the panel, the flange 27 having a lip 28 extending laterally therefrom at substantially a right angle thereto. The flanges 26 and 27 are apertured at suitable locations so that the panels may be joined to each other by juxtaposing a flange 26 of one panel with a flange 27 of the other panel and then bolting the two panels together by bolts extending through such apertures. In this arrangement, the lip 28 of each flange 27 overlaps the end of the flange 26 of the adjacent panel so as to form a tight enclosure. Other means of securing the panels in assembled relation will be made apparent as the description proceeds.

A panel or sheet 30, of plywood or the like, is mounted within the upright section 21 to extend in substantially a vertical plane, the sheet 30 being disposed between the flanges 26 and 27. Thus, the cylindrical surfaces and sheet form a tubular structure as shown in FIGS. 4 and 5, which adds a rigidity of construction to the overall shell of the present invention by reinforcing each panel unit to allow the shell to withstand the ravages of outdoor weather. Each sheet 30 is formed with a hand hole 31, and may be formed With additional openings, indicated at 32, which may have an effect upon the acoustical properties of the panel. Further, a plurality of cleats 33 are secured along each side of each sheet 30. Near the terminal end of the roof arch portion 22, a pair of eyestraps 34 are secured to the panel to receive straps or bungee assembles 36 to the tie adjacent panels together.

An important feature of the invention is the support by means of which each panel may be supported in proper position despite irregularities in the support surface. This support is in the form of an incomplete right triangle having aligned pivot ends 37, "37 a base portion 38 which extends perpendicular to the pivot axis, and a hypotenuse section 39. The pivot ends 37 are secured in the eyelet-s or the like 41 on the wood or plywood panel 30, and it will be noted that the pivot axis for the support bracket 35 extends at a relatively small acute angle to the relatively vertical side edges of each panel.

The importance of having the axis 40 extend at such an acute angle to a vertical line, or to a line which is perpendicular to the base edge of a panel 20, will be apparent from FIG. 3. Thus, depending upon the angular degree to which the bracket or support 35 is swung out from the back of the panel, its lower outer corner 42 will engage a support surface 43 at different levels. Thereby, the panel 20 may be held in a vertical position by the bracket 35 irrespective of minor differences in elevation of the support surface 43. To maintain the panel held in such vertical position, a sandbag, concrete block, or the like may be placed on top of the base section 38 of the bracket '35.

Another form of support for each panel 20 is indicated in FIG. 8 as a triangular brace formed of angle iron, such as 1 /2" x '1 /2" steel angle iron. Such a triangular brace is illustrated at 45. Brace 45 is in the form of a right triangle having an upright portion 46, a base 47, and an hypotenuse 48, all formed of angle iron. One of these braces is used at the adjoining edges of a pair of panels, a leg of the angle iron being .placed against a flange of a panel and secured thereto by bolts passing through the angle iron leg and the juxtaposed flange, and a single series of bolts both connecting the panels together and securing the braces 45 thereto at the abutting edges of adjoining panels.

While not restricted thereto, the bracket support or brace 35 may be used on panels intended for indoor use and the bracket support or brace 45 on panels intended for outdoor use. In the latter case, bases 47 are bolted to the support surface, such as a stage or platform.

Due to the tapering shape of the roof arch 22 of each panel, when the panels 20 are assembled with each other they form a curved shell as illustrated at 15 in FIG. 1. In order to form a straight shell using the panels 20, the arrangement shown in FIG. 9 is used. As therein illustrated, a triangular filler panel 50 is secured between each pair of adjacent roof arches 22, and straighten out the panel assembly so that the shell extends in a straight line.

FIG. 10 illustrates a modification by means of which an essentially longitudinally rectilinear shell may be formed. In this case, the panels 55 have parallel edges throughout their lengths, including the upright portions 51 and the roof arches 52 as well as the top border 53. It will be noted that this requires a panel 55 which differs from the panel 20, so that special panels are required in dependence upon whether the shell is to be curved longitudinally or is to be rectilinear in a longitudinal direction.

It will be noted that, using the panels of the invention, a shell of any desired type and contour can be easily and quickly erected using panels 20 or 55, or combinations of both types of panels. No bolting, nailing, or screwing to a stage floor or the like is necessary for indoor shells, as the panels may be readily supported by placing sandbags, concrete blocks, or the like, upon the bases of the support brackets 35. Considering their size, the panels are relatively light in weight so as to be easily transportable, and it will be further noted that the panels may be compactly nested with each other for storage and transportation purposes. The acoustical properties, due to the polycylindrical and forwardly convex surfaces of the shell are excellent, and the roof of the arch is integral with the upright portion thereof.

While specific embodiments of the invention have been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.

What is claimed is:

1. An upright acoustical panel comprising a sound directing panel and a reinforcing panel, said sound directing panel having a main portion and an upper portion, said main portion being concave-convex about a vertical axis and having flanges at the vertical side edges thereof, said flanges extending rearwardly in a direction opposite to said convex side of said main portion, said convex side defining the front of said panel, said reinforcing panel extending between said side flanges and overlying the concave side of said main portion, said upper portion extending forwardly in a smooth arc above said convex side, the outermost end of said upper portion being uniplanar about a horizontal axis, the intermediate section of said upper portion being concave-convex and merging smoothly between said uniplanar upper portion and said concaveconvex main portion.

2. An upright acoustical panel comprising a sounddirecting panel and a reinforcing panel, said sound-directing panel having a main portion and an upper portion, said main portion being concave-convex about a vertical aXis and having flanges at the vertical side edges thereof,

said flanges extending rearwardly in a direction opposite to said convex side of said main portion, said convex side defining the front of said panel, said reinforcing panel extending between said side flanges and overlying the concave side of said main portion, said upper portion extending forwardly in a smooth are above said convex side and having a substantially vertical outer end portion, the outermost end of said upper portion proximate said outer end portion being uniplanar about a horizontal axis, the intermediate section of said upper portion being concaveconvex and merging smoothly between said uniplanar upper portion and said concave-convex main portion.

3. An upright acoustical panel as defined in claim 1, wherein the vertical side edges of said main portion are equally spaced from one another and wherein the vertical side edges of said upper portion are spaced closer to one another at the outermost end of said upper portion than at the junction between said upper portion and said main portion whereby to define an acoustical panel which tapers inwardly toward the outer end thereof.

4. An upright acoustical panel as defined in claim 1 and further including a support brace extendable from said reinforcing panel to engage a support surface for the upright support of said acoustical panel, said support brace being in the form of a right triangle having one of its mutual perpendicular sides extending along the surface of said reinforcing panel, means cooperating between said support brace and said reinforcing panel for pivotally connecting said support brace to said reinforcing panel about an axis, said axis forming a small acute angle with a vertical side edge of said reinforcing panel whereby, depending upon the angular extent to which said brace is swung outwardly from said reinforcing panel, the support point of said brace will be at a corresponding different elevation.

5. An upright acoustical panel as claimed in claim 1, wherein said main portion includes at least two concaveconvex surfaces between said vertical side edges, the joint between adjacent concave-convex surfaces on the concave side thereof being proximate to the inner surface of said reinforcing panel whereby to define at least two hollow sections between said sound-directing panel and said reinforcing panel.

6. In an acoustical shell comprising a plurality of upright acoustical panels secured together in edgewise relationship to form said acoustical shell, each of said acoustical panels having a main portion and an upper portion, said upper portion extending forwardly in a smooth are above said main portion, the vertical side edges of at least two adjacent acoustical panels converging toward one another from the joint between the main portion and the upper portion toward the uppermost end of said upper portion and at least one triangular filler piece inserted between said upper portions of said adjacent pair of acous-' tical panels with the vertical side edges of said triangular filler piece secured to mating vertical side edges of said adjacent acoustical panels, said triangular filler piece having a dimension such that, when inserted between adjacent acoustical panel upper portions, the resulting shell defined by said adjacent acoustical panels and said triangular filler piece has the main portions of said adjacent acoustical panels in substantially the same vertical plane.

References Cited by the Examiner UNITED STATES PATENTS 795,646 7/ 1905 Plummer 25 6-26 1,220,032 3/ 1917 Volland 272-23 1,238,228 8/1917 Weil 52--67 2,683,002 7/1954 Adams et a1. 181--33 2,871,521 2/1959 Messmore 52-73 3,180,446 4/1965 Wenger 18l30 FOREIGN PATENTS 236,287 11/1961 Austria.

346,792 4/ 1931 Great Britain.

RICHARD B. WILKINSON, Primary Examiner.

R. S. WARD, Assistant Examiner. 

1. AN UPRIGHT ACOUSTICAL PANEL COMPRISING A SOUND DIRECTING PANEL AND A REINFORCING PANEL, SAID SOUND DIRECTING PANEL HAVING A MAIN PORTION AND AN UPPER PORTION, SAID MAIN PORTION BEING CONCAVE-CONVEX ABOUT A VERTICAL AXIS AND HAVING FLANGES AT THE VERTICAL SIDE EDGES THEREOF, SAID FLANGES EXTENDING REARWARDLY IN A DIRECTION OPPOSITE TO SAID CONVEX SIDE OF SAID MAIN PORTION, SAID CONVEX SIDE DEFINING THE FRONT OF SAID PANEL, SAID REINFORCING PANEL EXTENDING BETWEEN SAID SIDE FLANGES AND OVERLYING THE CONCAVE SIDE OF SAID MAIN PORTION, SAID UPPER PORTION EXTENDING FORWARDLY IN A SMOOTH ARC ABOVE SAID CONVEX SIDE, THE OUTERMOST END OF SAID UPPER PORTION BEING UNIPLANAR ABOUT A HORIZONTAL AXIS, THE INTERMEDIATE SECTION OF SAID UPPER PORTION BEING CONCAVE-CONVEX AND MERGING SMOOTHLY BETWEEN SAID UNIPLANAR UPPER PORTION AND SAID CONCAVECONVEX MAIN PORTION. 